US20050214542A1 - Plated automotive part and method - Google Patents
Plated automotive part and method Download PDFInfo
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- US20050214542A1 US20050214542A1 US11/086,355 US8635505A US2005214542A1 US 20050214542 A1 US20050214542 A1 US 20050214542A1 US 8635505 A US8635505 A US 8635505A US 2005214542 A1 US2005214542 A1 US 2005214542A1
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- plating
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
- C25D5/10—Electroplating with more than one layer of the same or of different metals
- C25D5/12—Electroplating with more than one layer of the same or of different metals at least one layer being of nickel or chromium
- C25D5/14—Electroplating with more than one layer of the same or of different metals at least one layer being of nickel or chromium two or more layers being of nickel or chromium, e.g. duplex or triplex layers
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
- C25D5/627—Electroplating characterised by the visual appearance of the layers, e.g. colour, brightness or mat appearance
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T24/00—Buckles, buttons, clasps, etc.
- Y10T24/34—Combined diverse multipart fasteners
- Y10T24/3401—Buckle
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T24/00—Buckles, buttons, clasps, etc.
- Y10T24/34—Combined diverse multipart fasteners
- Y10T24/3401—Buckle
- Y10T24/3413—Buckle and clasp
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
- Y10T428/12556—Organic component
- Y10T428/12569—Synthetic resin
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12708—Sn-base component
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12771—Transition metal-base component
- Y10T428/12861—Group VIII or IB metal-base component
- Y10T428/12937—Co- or Ni-base component next to Fe-base component
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12771—Transition metal-base component
- Y10T428/12861—Group VIII or IB metal-base component
- Y10T428/12944—Ni-base component
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/3154—Of fluorinated addition polymer from unsaturated monomers
Definitions
- the present invention relates to plated automotive parts and to methods of plating automotive parts.
- some automotive parts 10 are conventionally formed of a base metal 12 (e.g., steel) to which one or more layers of nickel (i.e., “Ni”) 14 is/are applied.
- An outer layer 16 of hexavalent chrome has conventionally been applied to the layers 14 of Ni to complete the plating of the base metal 12 .
- FIG. 2 a details a conventional method of plating parts of the type shown in FIG. 1 with hexavalent chrome.
- a base metal 12 is subjected to a pre-degreasing process.
- the base metal 12 is degreased.
- the degreased base metal 12 is subjected to water washing (one or more times).
- the washed base metal 12 is subjected to acid cleaning (i.e., pickling).
- step S 105 the base metal 12 is again subjected to water washing (one or more times).
- a semi-bright finish layer 14 A of Ni is plated onto the base metal 12 .
- step S 107 The once-plated base metal 12 is then allowed to cool (i.e., recover) in step S 107 .
- step S 108 a bright finish layer 14 B of Ni is plated onto the semi-bright layer 14 A of Ni.
- step S 109 the twice-plated base metal 12 is again allowed to recover.
- step S 110 chromium activation occurs.
- step S 111 an outer layer 16 of hexavalent chromium is plated onto the bright finish layer 14 B of Ni.
- step S 112 the plated base metal 12 is again allowed to recover.
- step S 113 the plated base metal 12 is subjected to water washing (one or more times).
- step S 114 the plated base metal 12 is subjected to hot water washing.
- chromium metal has a high surface hardness and excellent wear resistance and corrosion resistance.
- Hexavalent chromium is a specified toxic substance, and its use requires treatment of wastewater and exhaust air. Thus, manufacturers using hexavalent chromium must invest in, operate, and maintain a detoxification system and must pay additional costs to meet local regulatory requirements.
- FIG. 2 b details a conventional method of detoxifying wastewater and exhaust air generated during the process shown in FIG. 2 a .
- step S 201 which occurs during and/or after steps S 101 to S 105 in FIG. 2 a
- wastewater is treated to remove or neutralize alkali and acid.
- step S 202 which occurs during and/or after steps S 106 to S 109 in FIG. 2 a
- wastewater is treated to remove or neutralize Ni.
- step S 203 (which occurs during step S 1 of FIG.
- step S 204 (which occurs during and/or after steps S 110 to S 114 in FIG. 2 a ), wastewater is treated by a reduction treatment of hexavalent chromium to trivalent chromium.
- step S 205 (which occurs after step S 204 ), other chromium is treated.
- hexavalent chromium Even when the detoxification treatment is strictly managed, the use of hexavalent chromium presents environmental and safety risks. Such risks include leakage of hexavalent chromium from the manufacturing process potentially resulting in air, soil, and/or water contamination and adherence of hexavalent chromium to products potentially creating adverse health effects in persons exposed to the hexavalent chromium.
- manufacturers desiring to use hexavalent chromium must satisfy local regulatory requirements and obtain approval and licensing to use hexavalent chromium. Obtaining approval and licensing can be a lengthy process and, in some cases, approval may be impossible to obtain. Even if approval is obtained, risks to the manufacturer include production stoppages due to releases of hexavalent chromium, compensation paid to parties injured by hexavalent chromium contamination, and the cost of environmental cleanup due to hexavalent chromium pollution.
- chrome has proven to be an effective plating material, its use raises environmental concerns. What is needed, therefore, is an automotive plating and method of plating which, like chrome, provides effective plating properties but which is more environmentally friendly than chrome.
- a plated automotive part and method of plating are be provided.
- One or more semi-bright finish layers of nickel may be plated onto an automotive part.
- One or more bright finish layers of nickel may be plated onto the outermost, semi-bright finish layer of nickel.
- One or more layers of an alloy may be plated onto the outermost, bright-finish layer of nickel.
- the alloy has a Vickers hardness of 400 VHN or greater.
- FIG. 1 is a cross-sectional view of an automotive part covered with a conventional plating material
- FIG. 2 a is a block diagram of a conventional plating method
- FIG. 2 b is a block diagram of a conventional wastewater and exhaust air treatment method
- FIG. 3 is a cross-sectional view of an automotive part covered with a plating material according to an embodiment of the present invention
- FIG. 4 a is a block diagram of a plating method according to an embodiment of the present invention.
- FIG. 4 b is a block diagram of a plating method according to an embodiment of the present invention.
- FIG. 4 c is a block diagram of a wastewater treatment method according to an embodiment of the present invention.
- FIG. 5 is a perspective view of an embodiment of a plated automotive part according to the present invention.
- Embodiments of the present invention will be described below with reference to FIGS. 3-5 .
- an automotive part 110 includes a base metal 12 (e.g., steel) onto which one or more layers 14 of Ni are applied.
- a base metal 12 e.g., steel
- layers 14 of Ni are applied onto which one or more layers 14 of Ni are applied.
- the scope of the present invention includes plated parts and methods of plating involving any number of layers 14 of Ni.
- the outermost layer 14 of Ni is coated with a final layer 18 , which is an alloy plating.
- the alloy plating is preferably an Si/Ni alloy and preferably has a Vickers hardness of 400 VHN or greater.
- the thickness D 1 of the outer layer 18 is preferably less than or equal to about 20 ⁇ m.
- the thickness D 2 of the combined layers 14 , 18 is preferably less than or equal to about 100 ⁇ m.
- more than one layer may be appropriate for some applications and are, therefore, fully within the scope of the invention.
- FIG. 4 a discloses a method of plating automotive parts of the type shown in FIG. 3 according to an embodiment of the present invention.
- a base metal 12 is degreased.
- step S 2 the degreased base metal 12 is subjected to water washing.
- step S 3 the washed base metal 12 is subjected to acid pickling.
- step S 4 the pickled base metal 12 is again subjected to water washing.
- step S 5 a semi-bright finish layer 14 A of Ni is plated onto the base metal 12 .
- the once-plated base metal 12 is then allowed to recover in step S 6 .
- a bright finish layer 14 B of Ni is plated onto the semi-bright layer 14 A of Ni.
- step S 8 the twice-plated base metal 12 is again allowed to recover.
- step S 6 the method may return to step S 5 .
- one or more additional layers 14 A of semi-bright finish Ni may be added to the first layer 14 A of semi-bright finish Ni originally applied in step S 5 by successively repeating steps S 5 and S 6 .
- steps S 5 and S 6 Upon adding a satisfactory number of semi-bright finish layers 14 A of Ni, these method embodiments continue at step S 7 .
- step S 8 the method may return to step S 7 .
- one or more additional layers 14 B of bright finish Ni may be added to the first layer 14 B of bright finish Ni originally applied in step S 7 by successively repeating steps S 7 and S 8 .
- steps S 7 and S 8 Upon adding a satisfactory number of bright finish layers 14 B of Ni, these method embodiments continue at step S 9 A.
- step S 10 after step S 10 , the method may return to step S 9 A.
- one or more additional layers 18 of the alloy may be added to the first layer 18 of alloy originally applied in step S 9 A by successively repeating steps S 9 A and S 10 .
- these method embodiments are stopped after a completion of step S 10 .
- FIG. 4 b details a method of plating automotive parts of the type shown in FIG. 3 according to another embodiment of the present invention.
- a base metal 12 is subjected to a pre-degreasing process.
- the base metal 12 is degreased.
- the degreased base metal 12 is subjected to water washing (one or more times).
- the base metal 12 is preferably water washed two times.
- the washed base metal 12 is subjected to acid cleaning (i.e., pickling).
- step S 105 the base metal 12 is again subjected to water washing (one or more times).
- the base metal 12 is preferably subjected to water washing two times.
- step S 106 a semi-bright finish layer 14 A of Ni is plated onto the base metal 12 .
- the once-plated base metal 12 is then allowed to cool (i.e., recover) in step S 107 .
- step S 108 a bright finish layer 14 B of Ni is plated onto the semi-bright layer 14 A of Ni.
- step S 109 the twice-plated base metal 12 is again allowed to recover.
- step S 110 of the conventional method involves chromium activation
- step S 110 A of the present invention involves subjecting the base metal 12 to an alloy bath.
- the alloy bath is preferably an Sn/Ni alloy bath.
- step S 111 of the conventional method involves plating an outer layer 16 of hexavalent chromium onto the bright finish layer 14 B of Ni
- step S 111 A of the present invention involves plating an outer layer 18 of alloy onto the bright finish layer 14 B of Ni.
- the alloy is preferably an Si/Ni alloy.
- step S 112 the plated base metal 12 is again allowed to recover.
- step S 113 the plated base metal 12 is subjected to water washing (one or more times).
- the plated base metal 12 is preferably subjected to water washing two times.
- step S 114 the plated base metal 12 is subjected to hot water washing.
- step S 107 the method may return to step S 106 .
- one or more additional layers 14 A of semi-bright finish Ni may be added to the first layer 14 A of semi-bright finish Ni originally applied in step S 106 by successively repeating steps S 106 and S 107 .
- steps S 106 and S 107 Upon adding a satisfactory number of semi-bright finish layers 14 A of Ni, these method embodiments continue at step S 108 .
- step S 109 the method may return to step S 108 .
- one or more additional layers 14 B of bright finish Ni may be added to the first layer 14 B of bright finish Ni originally applied in step S 108 by successively repeating steps S 108 and S 109 .
- steps S 108 and S 109 Upon adding a satisfactory number of bright finish layers 14 B of Ni, these method embodiments continue at step S 110 A.
- step S 112 the method may return to step S 111 A.
- one or more additional layers 18 of the alloy may be added to the first layer 18 of alloy originally applied in step S 111 A by successively repeating steps S 111 A and S 112 .
- steps S 111 A and S 112 Upon adding a satisfactory number of alloy layers 18 , these method embodiments continue at step S 113 .
- FIG. 4 c details a method of treating wastewater according to an embodiment of the present invention. Specifically, in step S 201 (which preferably occurs during and/or after steps S 101 to S 105 in FIG. 4 b ), wastewater is treated to remove or neutralize alkali and acid. In step S 202 (which occurs during and/or after steps S 106 to S 109 in FIG. 4 b ), wastewater is treated to remove or neutralize Ni.
- step S 203 of the conventional method which involves capturing hexavalent chromium mist released into the atmosphere during chromium plating
- step S 204 of the conventional method which involves wastewater reduction treatment of hexavalent chromium to trivalent chromium and treatment of other chromium
- step S 205 which treats other chromium.
- wastewater is treated to remove or neutralize components of the alloy. For example, when an Sn/Ni allow is used, wastewater is treated to remove or neutralize Sn and Ni.
- the alloy plating may have a lower hardness and poorer wear resistance than conventional chromium plating.
- the plated part may be protected from wear by minimizing the friction against the surface of the plated part.
- components in frictional contact with the plated part e.g., a base and a latch of a seatbelt buckle
- FIG. 5 shows an automotive part 30 plated pursuant to the method described in FIG. 4 a or FIG. 4 b .
- the automotive part 30 may be, for example, a seatbelt tongue.
- the present invention is not limited to such tongues. Rather, the invention applies to any automotive part including, but not limited to, a seat belt buckle, a D-ring, a ball (which is part of a vehicle sensor mounted in a seat belt retractor), and other related automotive parts.
- the use of a specified toxic substance in the plating of automotive parts is eliminated so that environmental protection and human safety is improved, wastewater and exhaust air treatment is improved, and manufacturing cost is reduced.
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Abstract
A plated automotive part and method of plating are provided. One or more semi-bright finish layers of nickel are plated onto an automotive part. One or more bright finish layers of nickel are plated onto the outermost, semi-bright finish layer of nickel. One or more layers of an alloy are plated onto the outermost, bright-finish layer of nickel. The alloy has a Vickers hardness of 400 VHN or greater.
Description
- This application claims priority to and the benefit of U.S. Provisional Patent Application No. 60/555,961, filed Mar. 25, 2004. The aforementioned provisional application is incorporated by reference herein in its entirety.
- The present invention relates to plated automotive parts and to methods of plating automotive parts.
- As shown in
FIG. 1 , some automotive parts 10 are conventionally formed of a base metal 12 (e.g., steel) to which one or more layers of nickel (i.e., “Ni”) 14 is/are applied. Anouter layer 16 of hexavalent chrome has conventionally been applied to thelayers 14 of Ni to complete the plating of thebase metal 12. -
FIG. 2 a details a conventional method of plating parts of the type shown inFIG. 1 with hexavalent chrome. Specifically, in step S101, abase metal 12 is subjected to a pre-degreasing process. In step S102, thebase metal 12 is degreased. In step S103, the degreasedbase metal 12 is subjected to water washing (one or more times). In step S104, thewashed base metal 12 is subjected to acid cleaning (i.e., pickling). In step S105, thebase metal 12 is again subjected to water washing (one or more times). In step S106, asemi-bright finish layer 14A of Ni is plated onto thebase metal 12. The once-platedbase metal 12 is then allowed to cool (i.e., recover) in step S107. In step S108, abright finish layer 14B of Ni is plated onto thesemi-bright layer 14A of Ni. In step S109, the twice-platedbase metal 12 is again allowed to recover. In step S110, chromium activation occurs. In step S111, anouter layer 16 of hexavalent chromium is plated onto thebright finish layer 14B of Ni. In step S112, theplated base metal 12 is again allowed to recover. In step S113, theplated base metal 12 is subjected to water washing (one or more times). Finally, in step S114, theplated base metal 12 is subjected to hot water washing. - The chrome plating gives the automotive part an attractive appearance and protects the part from scratches and rust because chromium metal has a high surface hardness and excellent wear resistance and corrosion resistance. Hexavalent chromium, however, is a specified toxic substance, and its use requires treatment of wastewater and exhaust air. Thus, manufacturers using hexavalent chromium must invest in, operate, and maintain a detoxification system and must pay additional costs to meet local regulatory requirements.
-
FIG. 2 b details a conventional method of detoxifying wastewater and exhaust air generated during the process shown inFIG. 2 a. Specifically, in step S201 (which occurs during and/or after steps S101 to S105 inFIG. 2 a), wastewater is treated to remove or neutralize alkali and acid. In step S202 (which occurs during and/or after steps S106 to S109 inFIG. 2 a), wastewater is treated to remove or neutralize Ni. In step S203 (which occurs during step S1 ofFIG. 2 a), exhaust air is treated to remove hexavalent chromium by capturing hexavalent chromium mist released into the atmosphere during chromium plating and depositing the captured hexavalent chromium mist in the wastewater. In step S204 (which occurs during and/or after steps S110 to S114 inFIG. 2 a), wastewater is treated by a reduction treatment of hexavalent chromium to trivalent chromium. Finally, in step S205 (which occurs after step S204), other chromium is treated. - Even when the detoxification treatment is strictly managed, the use of hexavalent chromium presents environmental and safety risks. Such risks include leakage of hexavalent chromium from the manufacturing process potentially resulting in air, soil, and/or water contamination and adherence of hexavalent chromium to products potentially creating adverse health effects in persons exposed to the hexavalent chromium.
- Additionally, manufacturers desiring to use hexavalent chromium must satisfy local regulatory requirements and obtain approval and licensing to use hexavalent chromium. Obtaining approval and licensing can be a lengthy process and, in some cases, approval may be impossible to obtain. Even if approval is obtained, risks to the manufacturer include production stoppages due to releases of hexavalent chromium, compensation paid to parties injured by hexavalent chromium contamination, and the cost of environmental cleanup due to hexavalent chromium pollution.
- Thus, although chrome has proven to be an effective plating material, its use raises environmental concerns. What is needed, therefore, is an automotive plating and method of plating which, like chrome, provides effective plating properties but which is more environmentally friendly than chrome.
- According an exemplary embodiment of the invention, a plated automotive part and method of plating are be provided. One or more semi-bright finish layers of nickel may be plated onto an automotive part. One or more bright finish layers of nickel may be plated onto the outermost, semi-bright finish layer of nickel. One or more layers of an alloy may be plated onto the outermost, bright-finish layer of nickel. According to a preferred embodiment, the alloy has a Vickers hardness of 400 VHN or greater.
- It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention as claimed.
- These and other features, aspects, and advantages of the present invention will become apparent from the following description, appended claims, and the accompanying exemplary embodiments shown in the drawings, which are briefly described below.
-
FIG. 1 is a cross-sectional view of an automotive part covered with a conventional plating material; -
FIG. 2 a is a block diagram of a conventional plating method; -
FIG. 2 b is a block diagram of a conventional wastewater and exhaust air treatment method; -
FIG. 3 is a cross-sectional view of an automotive part covered with a plating material according to an embodiment of the present invention; -
FIG. 4 a is a block diagram of a plating method according to an embodiment of the present invention; -
FIG. 4 b is a block diagram of a plating method according to an embodiment of the present invention; -
FIG. 4 c is a block diagram of a wastewater treatment method according to an embodiment of the present invention; and -
FIG. 5 is a perspective view of an embodiment of a plated automotive part according to the present invention. - Embodiments of the present invention will be described below with reference to
FIGS. 3-5 . - As shown in
FIG. 3 , anautomotive part 110 includes a base metal 12 (e.g., steel) onto which one ormore layers 14 of Ni are applied. Moreover, although only two underlayers 14 of Ni are shown, the scope of the present invention includes plated parts and methods of plating involving any number oflayers 14 of Ni. - Regardless of the number of
layers 14 of Ni, theoutermost layer 14 of Ni is coated with afinal layer 18, which is an alloy plating. The alloy plating is preferably an Si/Ni alloy and preferably has a Vickers hardness of 400 VHN or greater. The thickness D1 of theouter layer 18 is preferably less than or equal to about 20 μm. Similarly, the thickness D2 of the combinedlayers outer layer 18 is contemplated in a normal application of the invention, more than one layer may be appropriate for some applications and are, therefore, fully within the scope of the invention. -
FIG. 4 a discloses a method of plating automotive parts of the type shown inFIG. 3 according to an embodiment of the present invention. Specifically, in step S1, abase metal 12 is degreased. In step S2, the degreasedbase metal 12 is subjected to water washing. In step S3, the washedbase metal 12 is subjected to acid pickling. In step S4, thepickled base metal 12 is again subjected to water washing. In step S5, asemi-bright finish layer 14A of Ni is plated onto thebase metal 12. The once-platedbase metal 12 is then allowed to recover in step S6. In step S7, abright finish layer 14B of Ni is plated onto thesemi-bright layer 14A of Ni. In step S8, the twice-platedbase metal 12 is again allowed to recover. - It should be recognized, as indicated by dashed lines in
FIG. 4 a, in some embodiments of the method, after step S6, the method may return to step S5. In these method embodiments, one or moreadditional layers 14A of semi-bright finish Ni may be added to thefirst layer 14A of semi-bright finish Ni originally applied in step S5 by successively repeating steps S5 and S6. Upon adding a satisfactory number of semi-bright finish layers 14A of Ni, these method embodiments continue at step S7. - Similarly, as indicated by dashed lines in
FIG. 4 a, in some embodiments of the method, after step S8, the method may return to step S7. In these method embodiments, one or moreadditional layers 14B of bright finish Ni may be added to thefirst layer 14B of bright finish Ni originally applied in step S7 by successively repeating steps S7 and S8. Upon adding a satisfactory number of bright finish layers 14B of Ni, these method embodiments continue at step S9A. - Finally, as indicated by dashed lines in
FIG. 4 a, in some embodiments of the method, after step S10, the method may return to step S9A. In these method embodiments, one or moreadditional layers 18 of the alloy may be added to thefirst layer 18 of alloy originally applied in step S9A by successively repeating steps S9A and S10. Upon adding a satisfactory number of alloy layers 18, these method embodiments are stopped after a completion of step S10. -
FIG. 4 b details a method of plating automotive parts of the type shown inFIG. 3 according to another embodiment of the present invention. Specifically, in step S101, abase metal 12 is subjected to a pre-degreasing process. In step S102, thebase metal 12 is degreased. In step S103, the degreasedbase metal 12 is subjected to water washing (one or more times). Thebase metal 12 is preferably water washed two times. In step S104, the washedbase metal 12 is subjected to acid cleaning (i.e., pickling). In step S105, thebase metal 12 is again subjected to water washing (one or more times). Thebase metal 12 is preferably subjected to water washing two times. In step S106, asemi-bright finish layer 14A of Ni is plated onto thebase metal 12. The once-platedbase metal 12 is then allowed to cool (i.e., recover) in step S107. In step S108, abright finish layer 14B of Ni is plated onto thesemi-bright layer 14A of Ni. In step S109, the twice-platedbase metal 12 is again allowed to recover. - Each of the above-described steps is similar to corresponding steps of the conventional method shown in
FIG. 2 a. However, whereas step S110 of the conventional method involves chromium activation, step S110A of the present invention involves subjecting thebase metal 12 to an alloy bath. The alloy bath is preferably an Sn/Ni alloy bath. Additionally, whereas the step S111 of the conventional method involves plating anouter layer 16 of hexavalent chromium onto thebright finish layer 14B of Ni, step S111A of the present invention involves plating anouter layer 18 of alloy onto thebright finish layer 14B of Ni. The alloy is preferably an Si/Ni alloy. - In step S112, the plated
base metal 12 is again allowed to recover. In step S113, the platedbase metal 12 is subjected to water washing (one or more times). The platedbase metal 12 is preferably subjected to water washing two times. Finally, in step S114, the platedbase metal 12 is subjected to hot water washing. - It should be recognized, as indicated by dashed lines in
FIG. 4 b, in some embodiments of the method, after step S107, the method may return to step S106. In these method embodiments, one or moreadditional layers 14A of semi-bright finish Ni may be added to thefirst layer 14A of semi-bright finish Ni originally applied in step S106 by successively repeating steps S106 and S107. Upon adding a satisfactory number of semi-bright finish layers 14A of Ni, these method embodiments continue at step S108. - Similarly, as indicated by dashed lines in
FIG. 4 b, in some embodiments of the method, after step S109, the method may return to step S108. In these method embodiments, one or moreadditional layers 14B of bright finish Ni may be added to thefirst layer 14B of bright finish Ni originally applied in step S108 by successively repeating steps S108 and S109. Upon adding a satisfactory number of bright finish layers 14B of Ni, these method embodiments continue at step S110A. - Finally, as indicated by dashed lines in
FIG. 4 b, in some embodiments of the method, after step S112, the method may return to step S111A. In these method embodiments, one or moreadditional layers 18 of the alloy may be added to thefirst layer 18 of alloy originally applied in step S111A by successively repeating steps S111A and S112. Upon adding a satisfactory number of alloy layers 18, these method embodiments continue at step S113. -
FIG. 4 c details a method of treating wastewater according to an embodiment of the present invention. Specifically, in step S201 (which preferably occurs during and/or after steps S101 to S105 inFIG. 4 b), wastewater is treated to remove or neutralize alkali and acid. In step S202 (which occurs during and/or after steps S106 to S109 inFIG. 4 b), wastewater is treated to remove or neutralize Ni. - Each of the above-described steps is similar to corresponding steps of the conventional method shown in
FIG. 2 b. However, the present invention eliminates step S203 of the conventional method, which involves capturing hexavalent chromium mist released into the atmosphere during chromium plating; eliminates step S204 of the conventional method, which involves wastewater reduction treatment of hexavalent chromium to trivalent chromium and treatment of other chromium; and eliminates step S205, which treats other chromium. In step S203A of the present invention, wastewater is treated to remove or neutralize components of the alloy. For example, when an Sn/Ni allow is used, wastewater is treated to remove or neutralize Sn and Ni. - In an automotive part plated according to the method embodiments described above, the alloy plating may have a lower hardness and poorer wear resistance than conventional chromium plating. Thus, according to an embodiment of the present invention, the plated part may be protected from wear by minimizing the friction against the surface of the plated part. To protect the plated part (e.g., a seatbelt tongue), components in frictional contact with the plated part (e.g., a base and a latch of a seatbelt buckle) may include a coating containing molybdenum disulfide or fluorocarbon resin powder or may be treated with manganese phosphate plating or zinc plating having lower hardness than that of the alloy plating.
-
FIG. 5 shows anautomotive part 30 plated pursuant to the method described inFIG. 4 a orFIG. 4 b. Theautomotive part 30 may be, for example, a seatbelt tongue. However, the present invention is not limited to such tongues. Rather, the invention applies to any automotive part including, but not limited to, a seat belt buckle, a D-ring, a ball (which is part of a vehicle sensor mounted in a seat belt retractor), and other related automotive parts. - Thus, according to embodiments of the present invention, the use of a specified toxic substance in the plating of automotive parts is eliminated so that environmental protection and human safety is improved, wastewater and exhaust air treatment is improved, and manufacturing cost is reduced.
- Given the disclosure of the present invention, one versed in the art would appreciate that there may be other embodiments and modifications within the scope and spirit of the invention. Accordingly, all modifications attainable by one versed in the art from the present disclosure within the scope and spirit of the present invention are to be included as further embodiments of the present invention. The scope of the present invention is to be defined as set forth in the following claims.
Claims (47)
1. A method of plating automotive parts comprising the steps of:
plating at least one semi-bright finish layer of Ni onto a base metal of an automotive part;
plating at least one bright finish layer of Ni onto the outermost semi-bright finish layer of Ni; and
plating an alloy layer onto the outermost bright finish layer of Ni,
wherein the alloy layer has a Vickers hardness of 400 VHN or greater.
2. The method according to claim 1 , wherein the alloy layer comprises an Sn/Ni alloy.
3. The method according to claim 1 , wherein a thickness of the alloy layer is about 20 μm or less.
4. The method according to claim 1 , wherein a thickness of the semi-bright finish layer, the bright finish layer, and the alloy layer is about 100 μm or less.
5. The method according to claim 1 , wherein the step of plating at least one semi-bright finish layer of Ni onto a base metal of an automotive part comprises plating at least two layers of semi-bright finish Ni.
6. The method according to claim 1 , wherein before the step of plating at least one semi-bright finish layer of Ni onto a base metal of an automotive part, the method further comprises the step of:
degreasing the base metal.
7. The method according to claim 6 , wherein after the step of degreasing the base metal, the method further comprises the steps of:
washing the degreased base metal;
pickling the washed base metal in acid; and
washing the pickled base metal.
8. The method according to claim 1 , wherein before the step of plating at least one semi-bright finish layer of Ni onto a base metal of an automotive part, the method further comprises the steps of:
pickling the base metal in acid; and
washing the pickled base metal.
9. The method according to claim 1 , wherein after the step of plating at least one semi-bright finish layer of Ni onto a base metal of an automotive part the method comprises the step of recovering the base metal having the at least one semi-bright finish layer of Ni thereon.
10. The method according to claim 9 , wherein after the step of plating at least one bright finish layer of Ni onto the outermost semi-bright finish layer of Ni the method comprises the step of recovering the base metal having the layers of semi-bright finish and bright-finish Ni thereon.
11. The method according to claim 10 , wherein after the step of plating an alloy layer onto the outermost bright finish layer of Ni the method comprises the step of:
recovering the base metal having the layers of semi-bright finish Ni, bright-finish Ni, and alloy plating thereon.
12. The method according to claim 11 , wherein the alloy plating comprises Sn/Ni.
13. A method of plating automotive parts comprising the steps of:
degreasing a base metal of an automotive part;
washing the degreased base metal;
pickling the washed base metal in acid;
washing the pickled base metal;
plating at least one semi-bright finish layer of Ni onto the base metal;
plating at least one bright finish layer of Ni onto the outermost semi-bright finish layer of Ni; and
plating an alloy layer onto the outermost bright finish layer of Ni.
14. The method according to claim 13 , wherein the alloy layer comprises Sn/Ni.
15. The method according to claim 13 , wherein before the step of decreasing the base metal of the automotive part, the method further comprises pre-degreasing the base metal of the automotive part.
16. The method according to claim 13 , wherein before the step of plating an alloy layer onto the outermost bright finish layer of Ni, the method further comprises subjecting the base metal 12 of the automotive part to an alloy bath.
17. The method according to claim 16 , wherein the alloy bath comprises an Sn/Ni alloy bath.
18. The method according to claim 13 , wherein after the step of plating an alloy layer onto the outermost bright finish layer of Ni, the method further comprises the steps of:
recovering the base metal having the layers of semi-bright finish Ni, bright-finish Ni, and alloy plating thereon;
washing the base metal having the layers of semi-bright finish Ni, bright-finish Ni, and alloy plating thereon; and
washing the base metal having the layers of semi-bright finish Ni, bright-finish Ni, and alloy plating thereon with hot water.
19. The method according to claim 13 , wherein the step of plating at least one semi-bright finish layer of Ni onto the base metal comprises plating at least two layers of semi-bright finish Ni.
20. The method according to claim 13 , wherein after the step of plating at least one semi-bright finish layer of Ni onto the base metal, the method further comprises recovering the base metal having the at least one semi-bright finish layer of Ni thereon.
21. The method according to claim 20 , wherein after the step of plating at least one bright finish layer of Ni onto the outermost semi-bright finish layer of Ni, the method further comprises recovering the base metal having the layers of semi-bright finish and bright-finish Ni thereon.
22. The method according to claim 21 , wherein after the step of plating an alloy layer onto the outermost bright finish layer of Ni, the method further comprises recovering the base metal having the layers of semi-bright finish Ni, bright-finish Ni, and alloy thereon.
23. The method according to claim 22 , wherein the alloy comprises Sn/Ni.
24. A plated automotive part comprising:
a base metal;
a Ni layer on the base metal; and
an outermost plating layer including an alloy,
wherein the outermost plating layer has a Vickers harness of 400 VHN or greater.
25. The part of claim 24 , wherein the alloy comprises Sn/Ni.
26. The part of claim 24 , wherein the Ni layer includes a semi-bright finish layer directly on the base metal.
27. The part of claim 26 , wherein the Ni layer includes a bright finish layer overlying the semi-bright finish layer.
28. The plated automotive part of claim 24 , wherein a thickness of the alloy layer is less than about 20 μm.
29. The plated automotive part of claim 24 , wherein a combined thickness of the layers is less than about 100 μm.
30. The plated automotive part of claim 27 , wherein a combined thickness of the layers is less than about 100 μm.
31. The plated automotive part of claim 24 , wherein the plated automotive part is configured to engage a corresponding automotive part, and wherein a surface of the corresponding automotive part configured to contact the plated automotive part has a hardness lower than the harness of the outermost plating layer of the plated automotive part.
32. The plated automotive part of claim 31 , wherein the surface of the corresponding automotive part includes a coating containing molybdenum disulfide.
33. The plated automotive part of claim 31 , wherein the surface of the corresponding automotive part includes a coating containing fluorocarbon resin powder.
34. The plated automotive part of claim 31 , wherein the surface of the corresponding automotive part includes a manganese phosphate plating.
35. The plated automotive part of claim 31 , wherein the surface of the corresponding automotive part includes a zinc plating.
36. A seat belt tongue comprising an outermost plating layer including an alloy having a Vickers hardness of 400 VHN or greater.
37. The tongue of claim 36 , wherein the alloy comprises Sn/Ni.
38. The tongue of claim 36 , wherein a thickness of the outermost plating layer is less than about 20 μm.
39. The tongue of claim 36 , wherein the outermost plating layer overlies at least one Ni layer.
40. The tongue of claim 39 , wherein a combined thickness of the layers is less than about 100 μm.
41. The tongue of claim 36 , wherein the tongue is configured to engage a seat belt buckle having a base and a latch, and wherein a hardness of a surface of the base and a hardness of a surface of the latch are lower than the harness of the outermost plating.
42. The tongue of claim 41 , wherein the surfaces of the base and the latch include a coating containing molybdenum disulfide.
43. The tongue of claim 41 , wherein the surfaces of the base and the latch include a coating containing fluorocarbon resin powder.
44. The tongue of claim 41 , wherein the surfaces of the base and the latch include a manganese phosphate plating.
45. The tongue of claim 41 , wherein the surfaces of the base and the latch include a zinc plating.
46. A method of treating wastewater generated during plating of automotive parts comprising the steps of:
treating the wastewater to remove alkali and acid;
treating the wastewater to remove Ni; and
treating the wastewater to remove elements of an alloy plating.
47. The method of claim 46 , wherein the elements of the allow plating comprise Sn and Ni.
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WO2012084262A1 (en) * | 2010-12-23 | 2012-06-28 | Coventya S.P.A. | Substrate with a corrosion resistant coating and method of production thereof |
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WO2012084262A1 (en) * | 2010-12-23 | 2012-06-28 | Coventya S.P.A. | Substrate with a corrosion resistant coating and method of production thereof |
EP2655702B1 (en) | 2010-12-23 | 2016-04-06 | COVENTYA S.p.A. | Substrate with a corrosion resistant coating and method of production thereof |
US10011913B2 (en) | 2010-12-23 | 2018-07-03 | Coventya S.P.A. | Substrate with a corrosion resistant coating and method of production thereof |
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